Method of aligning terminal leads



July 25, 1961 A. Ross EI'AL 2,993,262

METHOD OF ALIGNING TERMINAL LEADS Filed July 2, 1956 5 Sheets-Sheet 1ggza IN VEN TOR:

Tiff/R ATTORNEYS July 25, 1961 A. ROSS ET AL METHOD OF ALIGNING TERMINALLEADS Filed July 2, 1956 3 Sheets-Sheet 2 INVENTORS 7 EM ATTORNEY- July25, 1961 A. ROSS ETAL 2,993,262

METHOD OF ALIGNING TERMINAL LEADS Filed July 2, 1956 3 Sheets-Sheet 3751 761' -76 Q6 BHE 8 1E III.

\gg o4 INVENTORS United States Patent 2,993,262 METHOD OF ALIGNINGTERMINAL LEADS Albert Ross and Solen M. Golfstein, Dayton, Ohio, as-

signors to Standard Electrical Products Company, a corporation of OhioFiled July 2, 1956, Ser. No. 595,379 11 Claims. (Cl. 29-1555) Thisinvention relates to means and method of aligning a plurality ofelongate members. This invention relates more particularly to a meansand method of aligning conductor members. The invention relates stillmore particularly to a means and method of aligning electricalconductors of an electrical device. The invention relates still moreparticularly to a means and method of aligning electrical terminals ofwindings of small electrical transformers. However, the invention is notso limited in that the invention is applicable for aligning and locatingnumerous types of elements.

Present day electrical panels and connection boards have the electricaldevices attached thereto after the connection circuits and leads of theboard or panel are completed.

In some panels and boards the leads and wires connecting various devicesof the panel are assembled and attached to the panel. In other panelsand boards the leads connecting the various devices are printed upon thepanel. However, regardless of the system used for applying connectionleads which connect between devices of a panel, the terminals of theconnection leads are positioned prior to the mounting of the electricaldevices upon the panel or board. Therefore, the positions of theterminals of the electrical devices to be mounted upon such panels andboards is predetermined and must be accurate and precise so that theterminals of the panel connection leads may be readily attached to theterminals of the electrical devices.

In regard to electrical transformers which are attached to such panels,numerous problems exist in positioning and forming the terminals orterminal leads. The terminal leads of the transformers are usually onlyapproximately positioned during assembly and must be formed and alignedas desired after the coil and core of the transformer are assembled.Furthermore, the terminals are somewhat flexible and may be deformedduring handling procedures before the devices are mounted. It istherefore desirable to apply some type of terminal connector plate orboard to the transformer to correctly position the terminals and torigidly maintain the terminals in desired positions.

Attempts have been made to use terminal connector boards with smallapertures for accurately positioning the terminals of smalltransformers. However, it has been found that it is necessary to havevery small apertures in the boards in order to obtain accurate spacingof the terminals. Therefore, it is extremely difficult to move thetransformer terminals through the apertures of these connector plates.Thus, the process of attaching a connector plate to a transformer hasbeen somewhat tedious and time consuming. Furthermore, it has been foundthat during the process of inserting the terminal leads through thesmall apertures for accurate positioning of the terminals, such severebending of some of the terminals has been necessary that the terminalsor the connections to the windings have been damaged. Also, with suchconnector boards, objectionable longitudinal stresses are transmitted tothe fragile internal coil connections.

It is an object of this invention to provide a means and method ofaccurately and easily aligning and positioning electrical conductormembers of electrical devices.

It is another object of this invention to provide a 2,993,262 PatentedJuly 25, 1961 method of simultaneously, accurately and preciselyaligning all of the terminals of an electrical transformer.

It is another object of this invention to provide such means and methodof aligning electrical conductor members which method may be readilycarried out in a production line manner or in an automation procedure.

It is another object of this invention to provide means for accuratelyand precisely positioning terminal leads of a transformer so that thetransformer may be mounted and connected by automatically operatingmachinery.

It is another object of this invention to provide a means and method offorming terminal leads of a transformer which method eliminates thepossibility of transmission of objectionable mechanical stresses fromthe terminal to the coil.

Another object of this invention is to provide means for increasing therigidity of terminals of transformers.

Other objects and advantages reside in the construction of parts, thecombination thereof, the mode of operation, and the method ofmanufacture, as will become more apparent from the followingdescription.

In the drawings:

FIGURE 1 is a side elevational view showing a typical transformer, theterminal connector leads of which may be readily and accuratelypositioned by the means and method of this invention. FIGURE 1 alsoshows, in section, an aligning plate which is used in connection withthis invention.

FIGURE 2 is a perspective view on a somewhat reduced scale of thetransformer and aligning plate shown in FIGURE 1.

FIGURE 3 is a side elevational view of the transformer and aligningplate of FIGURES 1 and 2 showing engagement between the transformer andthe aligning plate for proper positioning of the terminals of thetransformer.

FIGURE 4 is a side elevational view showing the transformer and aligningplate of FIGURES 1, 2 and 3 with the aligning plate in full engagementwith the transformer and with the terminals of the transformer properlyaligned and secured in such positions.

FIGURE 5 shows a typical transformer, the terminals of which may bealigned and positioned by the method of this invention. FIGURE 5 shows,in section, a modification of the aligning plate of this invention.

FIGURE 6 is a side elevational view of the transformer and aligningplate of FIGURE 5 with the aligning plate secured to the transformer.

FIGURE 7 is a fragmentary top plan view showing an aligning jig or blockof this invention.

FIGURE 8 is a section view taken substantially on line 8-8 of FIGURE 7.

FIGURE 9 is a side elevational view showing the transformer aligningplate of FIGURES 5 and 6 and showing the aligning block of FIGURE 7 infull engagement for properly aligning and positioning the terminalconnector leads of the transformer.

FIGURE 10 is a perspective view showing another modification of analigning plate of this invention and a typical transformer for usethereof.

FIGURE 11 is a side elevational view showing the transformer andaligning plate of FIGURE 10 with the aligning plate in engagement withthe transformer.

FIGURE 12 is a side elevational view similar to FIGURE 11 but showinganother position of engagement between the transformer and the aligningplate.

FIGURE 13 is a perspective view showing a modification in the assemblyof a transformer and aligning plate of this invention.

FIGURE 14 is a fragmentary side elevational view, with parts shown insection, of a typical transformer and another modification in analigning means of this invention.

FIGURE is a fragmentary side elevational view of the transformer shownin FIGURE 14. This figure also shows an aligning jig for alignment ofthe transformer terminal leads and means for clamping the terminal leadsin aligned positions.

Referring to the drawings in detail, FIGURES 1, 2, 3 and 4 show the useof an alignment plate 16 which is adapted for use in accuratelypositioning terminal leads 18 of a transformer 20 which is provided witha core 21 and a coil 23.

The alignment plate 16 is used for accurately positioning the terminalleads 18 one with respect to the other and for positioning the terminalleads 18 with respect to mounting studs 22 of the transformer 28. Thealignment plate 16 may preferably be made of any suitable insulationmaterial and is provided with a plurality of eyelet members 24, therebeing one eyelet member 24 for each of the terminal leads 18. Each ofthe eyelet members 24 has a conical portion 26 and a cylindrical portion28.

The alignment plate 16 is used to align and position all of the terminalleads 18. This aligning and positioning of the terminal leads 18 isaccomplished by relative movement between the transformer 20 and thealignment plate 16 in a manner as shown in FIGURE 3. During thisrelative movement, one toward the other, the mounting studs 22 passthrough slots 30 in the alignment plate 16 and the terminal leads 18 aredirected by the conical portion 26 of the eyelet members 24 as theterminal leads 18 are slightly bent by the conical portion 26. Thus, theter minal leads 18 move into the cylindrical portion 28 of the eyeletmembers 24. The opening at the vertex of the conical portion 26 and theopening in the cylindrical portion 28 is only large enough to slidablyreceive a terminal lead 18. The alignment plate 16 is moved with respectto the transformer 28 until the alignment plate 16 engages the core 21as shown in FIGURE 4.

Therefore, the relative predetermined positions of the terminal leads 18 one with respect to the other and with respect to the mounting studs22 is precisely obtained.

The transformer 20 is provided with a plurality of prongs 32 which arebent in the manner shown in FIG- URE 4 to firmly retain the alignmentplate 16 in engagement with the core 21. After the alignment plate 16 isso positioned solder or the like, or any suitable solidifiable material,as indicated by reference numeral 34, may be used to secure the terminalleads 18 to the eyelet members 24. Also, any other suitable means may beused to secure the terminal leads 18 within the eyelet members 24. Thus,the terminal leads 18 are rigidly maintained in desired position.

The transformer 20 may then be mounted upon a connection panel by meansof the mounting studs 22 and the terminal leads 18 are accurately andprecisely positioned in a predetermined manner with respect to otherelements of the panel.

In FIGURES 5, 6, 7, 8 and 9, a preferred modification of the means andmethod of this invention is disclosed. A typical transformer having acoil 42, a core 44, and terminals 46 is shown. The transformer 40 isalso provided with mounting lugs 48 and clamping prongs 58. Theterminals 46 are positioned in approximately the desired positions whenthe assembly of the transformer 40 has progressed to the stage shown inFIGURE 5.

An alignment plate 54 is provided with cylindrical eyelets 56 forreceiving the terminals 46. The apertures of eyelets 56 are considerablylarger than the terminals 46 so that the terminals 46 may easily moveinto the eyelets 56. The alignment plate 54 is also provided with slots58 for receiving the mounting lugs 48 of the transformer 40. Thealignment plate 54 is moved with respect to the transformer 40 so thatthe alignment plate 54 comes into engagement with the core 44 of thetransformer 40, as shown in FIGURE 6. During the movement of thealignment plate 54 with respect to the transformer 40, the terminals 46move through the cylindrical eyelets 56 and the mounting lugs 48 movethrough the slots 58 of the alignment plate 54. The terminals 46 arethus retained in approximate desired positions by means of thecylindrical eyelets 56. Then the clamping prongs 50 which are on eitherside of the core 44, are bent over to firmly secure the alignment plate54 to the transformer 40, as shown in FIGURE 6.

An aligning jig or block 60 is then used to accurately form and positionthe terminals 46. The aligning block 60 is provided with a plurality ofapertures 62 extending through the block 60. Each of the apertures 62has a tapered or conical portion 64 at one end thereof and a cylindricalportion 66 at the other end thereof and joining the conical portion 64.The aligning jig 60 is also provided with a plurality of slots ornotches 67 for receiving the mounting lugs 48. If desired, the slots ornotches 67 may have tapered edges, as shown, to aid in directing themounting lugs into the notches or slots 67.

With the terminals 46 positioned in the manner shown in FIGURE 6, thelower portion of the transformer 40 may be dipped into a body of moltensolder or the like or any suitable molten material so that moltenmaterial fills the apertures of the eyelets 56. With the solder, or thelike, in a molten condition filling the apertures of the eyelets 56 andengaging the terminals 46, the terminals 46 are inserted into theapertures 62 and the lugs 48 are inserted into the notches 67 of theblock 60 as the transformer 40 and the alignment plate 54 are moved onewith respect to the other, as shown in FIGURE 9. A plurality of recesses69 are provided in the aligning jig 60 for receiving the bent-overclamping prongs 50.

The terminals 46 enter the tapered portion 64 of the apertures 62. Theterminals '46 are thus guided by the tapered portions 64 into thecylindrical portion 66 of the apertures 62. The terminals 46, which areonly slightly smaller than the cylindrical portion 46 of the apertures62, are thus accurately positioned, as shown in FIGURE 9. While theterminals 46 are thus positioned in the aligning apertures 62 of thealigning jig 60, the solder 68 is allowed to solidify. In FIGURE 9, thesolder is indicated by reference numeral 68. Thus, the terminals 46 arefirmly retained within the eyelets 56 and are in proper alignedposition, one with respect to the other and with respect to the mountinglugs 48. Thus, the transformer 40 may be mounted upon any suitableprearranged panel and the terminals 46 are precisely positioned withrespect to the terminals on the panel to which they are to be connected.

As a modification of the procedure in the use of an aligning jig 60, theterminals 46 may be inserted into the apertures 62 and the mounting lugs48 inserted into the slots 67 of the aligning jig 60 before solder orthe like is applied to the terminals 46 and to the eyelets 56.Therefore, after the terminals 56 and the mounting lugs 48 are properlyaligned by the aligning jig 60, solder or the like is applied and ispermitted to solidify while the terminals 46 remain within the alignmentblock 60. Then by relative movement between the aligning block 60 andthe transformer 40, the terminals 46 and the mounting lugs 48 arewithdrawn from the aligning block 60.

In FIGURES 10, l1 and 12, a transformer 70 of a conventional type havinga core 72, a coil 74 and terminals 76 is shown. An aligning plate 78 isprovided for locating the terminals 76. The aligning plate 78 isprovided with a plurality of eyelets 80 extending through the aligningplate 78. The eyelets 80 may be similar to the eyelets 56 shown inFIGURES 5, 6 and 9. At the central portion of the aligning plate 78 anelongate opening 82 is provided.

The aligning plate 78 is moved relative to the transformer 70 so thatthe elongate opening 82 receives a portion of the core 72 and each ofthe eyelets 80 receives one of the terminals 76, as shown in FIGURE 11.If

desired, the transformer 70 and the aligning plate 78 may be moved onewith respect to the other a further distance so that the positionsthereof are as shown in FIGURE 12 with the aligning plate 78 injuxtaposed relation with the coil 74.

With the terminals 76 and the aligning plate 78 positioned-in the mannershown in FIGURE 11 or as shown in FIGURE 12, an aligning jig such as thealigning jig 60 shown in FIGURES 7, 8 and 9 may be used to accuratelyand precisely align the terminals 76 as solder or other suitablesolidifiable material is applied immediately before or after theterminals 76 are precisely positioned and located by the aligning jig.

FIGURE 13 shows a transformer 90 provided with a core 92, a coil 94, andterminal leads 96. During the assembly of the coil 94 and the core 92,an aligning plate 98 is positioned in engagement with the coil 94 sothat the terminal leads 96 extend through eyelets 100 of the aligningplate 98 as shown in FIGURE 13. The aligning plate 98 encompasses aportion of the core 92 and is disposed between a portion of the core 92and the coil 94. The eyelets 100 may be similar to the eyelets 80 shownin FIGURES 10, 11 and 12. An aligning jig such as the aligning jig 60shown in FIGURES 7, 8 and 9 may be used to simultaneously, accuratelyand precisely align all of the terminal leads 96 as discussed above.Solder or the like may be applied to the terminal leads 96 and to theeyelets 100 to rigidly retain the position of the terminal leads 96 onewith respect to the other and with respect to the core 92.

FIGURES 14 and 15 show another modification in the method and means ofthis invention for positioning and retaining terminal leads. A typicaltransformer 110 has a core 111 and a coil 112 with terminal leads 113extending therefrom. The transformer 110 is also provided with mountingstuds 116.

An aligning plate or terminal board 118 is attached to the transformer110 in a manner described above with respect to the alignment plate 54.The terminal board 118 is provided with eyelets 120, there being oneeyelet 120 for eachof the terminal leads. Each of the eyelets 120 has anend portion 122 extending from the terminal board 118.

When the terminal board 118 is attached to the transformer 110, theterminal leads 113 extend freely through the eyelets 122, as shown inFIGURE 14. By relative movement between the transformer 110 and analigning jig 126, the terminal leads 113 are precisely aligned andpositioned in a predetermined manner, as shown in FIG- URE 15. With theterminal leads 113 thus positioned in conical apertures 128 of thealignment jig 126, the end portions 122 of the eyelets 120 are crimpedor bent into firm engagement with the terminal leads 113, as shown inFIGURE 15. This engagement of the eyelets 120 with the terminal leads113 secures the terminal leads 113 in the desired spaced relationship,one with respect to the other, and with respect to the mounting lugs116. The transformer 110 and the alignment jig 126 are then disengaged,one from the other, so that the transformer 110 with the terminal leads113 is in condition for accurate mounting in a predetermined manner.

It is to be understood that the process of aligning terminal leads of anelectrical device by means of this invention simultaneously positionsall of the terminal leads. Such positioning is accurately and preciselyperformed. It is also to be understood that all of the operationsdiscussed above for precisely aligning terminal leads and formaintaining the alignment thereof may be carried out byautomatically'operated machinery so that very little, if any, of thework is carried out manually.

Thus, by means of this invention many types of electrical devices mayhave the terminal leads thereof rapidly, accurately, and preciselypositioned one with respect to' the other and with respect to otherelements of the devices. Therefore, the electrical devices may bemounted upon any suitable prearranged panels so that the terminals ofthe electrical devices are accurately positioned with respect to otherelements previously applied to the panel. The accurate and precisealignment of terminal leads by the means and method of this inventionpermits the electrical devices to be mounted and connected by means ofautomatically operated apparatus.

Although the preferred embodiment of the device has been described, itwill be understood that within the purview of this invention variouschanges may be made in the form, details, proportion and arrangement ofparts,

the combination thereof and mode of operation, which generally statedconsist in a device capable of carrying out the objects set forth, asdisclosed and defined in the appended claims.

Having thus described our invention, we claim:

1. In a method of producing a transformer of the type provided with acore and a coil having terminal leads provided with extending portions,the transformer being provided with mounting lugs for association withmounting means of a panel, said method serving to position the extendingportions of the terminal leads of the coil in a predetermined spacedrelationship one with respect to the other and with respect to themounting lugs comprising the provision of an alignment plate providedwith a plurality of conical eyelets to receive the extending portions ofthe terminal leads and provided with a plurality of apertures to receivethe mounting lugs, there being one eyelet for each of the terminalleads, there being one aperture for each of the mounting lugs, theapexes of the conical eyelets being in the predetermined relative spacedrelationship desired for the terminal leads, the terminal leads beingonly slightly smaller than the opening at the apex of the eyelets sothat the terminal leads are slidably movable through the eyelets, theapertures being only slightly larger than the mounting lugs, moving thealignment plate with respect to the transformer so that all of theterminal leads simultaneously move through their respective eyeletswhile all of the mounting lugs move through their respective apertures,the terminal leads thus being moved into desired predetermined spacedrelationship one with respect to the others and with respect to themounting lugs, attaching the alignment plate to the transformer with themounting lugs inserted through the apertures and with the terminal leadsinserted through the conical eyelets with the larger end of the conicaleyelets being directed toward the coil, the terminal leads thus beingmaintained in desired predetermined spaced relationship one with respectto the other and with respect to the mounting lugs of the transformer sothat the terminal leads may be readily and directly connected to otherelements of a panel which are at predetermined spaced positions withrespect to the mounting means of the panel.

2. A method of positioning terminal leads of a transformer provided witha core and coil comprising providing a positioning plate having anopening to receive the core and having a plurality of apertures, theopening in the plate being only slightly larger than the core so thatthe core may fit closely within the opening so that there is no lateralmovement of the plate with respect to the core there being one aperturefor each of the terminal leads of the transformer, each aperture beingsomewhat larger than the cross section of the terminal lead extendingtherethrough so that each terminal lead may move laterally within itsrespective aperture followed by relative movement between thetransformer and the plate so that the plate encompasses a portion of thecore adjacent the terminal leads with one of the terminal leadsextending through each of the apertures, followed by positioning all ofthe leads simultaneously in a jig having a plurality of taperedrecesses, there being one tapered recess to receive each of the terminalleads, the tapered.

recesses being at positions desired for the leads one with respect tothe others and with respect to the core, at least some of the leadsmoving laterally within their respective apertures during saidpositioning of the leads, followed by applying solidifiable material toeach of the terminal leads and to the plate to secure the terminal leadsin desired position with respect to the plate, followed by relativemovement between the jig and the transformer disengaging the terminalleads from the jig, the positioning plate thus maintaining the terminalleads in the positions thereof established by the jig, the terminalleads thus being retained and supported in desired relationship withrespect to the core and with respect to each other.

3. A method of positioning a plurality of conductor members of anelectrical apparatus having mounting means so that the conductor membersare positioned in a predetermined relationship with respect to themounting means and in a predetermined spaced-apart relation comprisingthe provision of a plurality of spaced-apart hollow conical members openat both ends thereof, positioning the conical members by relativemovement between the electrical apparatus and the conical members sothat the apexes of the conical members are in precise predeterminedposition one with respect to the other and relative to the mountingmeans, said relative movement between the conical members and theelectrical apparatus being in a direction so that all of the conductormembers substantially simultaneously enter the larger end of the conicalmembers and are directed through the apexes thereof so that all of theconductor members are simultaneously positioned one with respect to theother and with respect to the mounting means as determined by the apexesof the conical members, securing the conical members with respect to theelectrical apparatus, the conductor members thus being held in thepredetermined positions thereof relative to the mounting means and inpredetermined spaced-apart relationship.

4. In a method of positioning extending portions of the terminal leadsof an electrical device so that the portions are firmly positioned indesired predetermined spaced-apart relation and in desired relation withrespect to the electrical device, comprising the steps of insertingextending portions of all of the terminal leads simultaneously throughan aligning plate having a plurality of apertures, there being oneaperture for each terminal lead, each extending portion of a terminallead being laterally movable within its respective aperture, followed byattachment of the aligning plate to the electrical device, followed byapplying molten solidifiable material to the extending portions of theterminal leads and permitting the molten material to engage the edges ofthe apertures, followed by placing the extending portions of all of theterminal leads simultaneously into a group of spaced-apart conicalaligning members, there being one conical aligning member for each ofthe terminal leads, the apexes of the conical aligning members being inthe spaced-apart relationship and in the positions thereof with respectto the electrical device desired for the extending portions of theterminal leads, the aligning members thus causing all of the extendingportions of the terminal leads to be simultaneously positioned in thedesired spaced-apart relationship and in the desired relationship withrespect to the electrical device, followed by retaining the extendingportions of the terminal leads in said aligning'members until the moltenmaterial becomes solidified so that the extending portions of theterminal leads are secured in desired relative positions and in thedesired positions relative to the electrical de- ,vice, followed byremoval of the terminal leads from the aligning members.

5. A method of producing a transformer of the type having a core and acoil assembly provided with semiflexible terminal leads extending fromthe coil so that the terminal leads are accurately disposed andmaintained in desired predetermined positions one with respect to theother and with respect to the core, comprising providing a positioningplate having a plurality of apertures therein, there being one aperturefor each of the terminal leads, each of the terminal leads beingconsiderably smaller than its respective aperture and laterally movabletherein, the apertures being approximately spaced in the manner desiredfor the terminal leads, attaching the positioning plate to the assemblywith one of the terminal leads extending through each of the apertures,the plate being attached so that the terminal leads are positioned inthe approximate desired positions thereof with respect to the assembly,followed by engaging all of the terminal leads simultaneously with analigning means which moves the terminal leads with respect to theapertures and positions the terminal leads in the desired predeterminedspaced-apart positions, positioning the aligning means with respect tothe transformer so that the terminal leads are positioned at the desiredpredetermined positions with respect to the assembly, followed byapplication of molten solidifiable material to the portions of theterminal leads within the apertures of the positioning plate so that themolten material engages the sides and edges of the apertures as well asthe terminal leads, followed by permitting the material to solidify,thus firmly positioning the terminal leads in the desired locations,followed by disengagement between the terminal leads and the aligningmeans so that the terminal leads are firmly retained by the positioningplate in the desired locations thereof one with respect to the other andwith respect to the assembly.

6. In a method of bending and positioning flexible terminal leads of anelectrical device having mounting means adapted to be received bymounting means of a board or panel so that the terminal leads are firmlypositioned in desired predetermined spaced relation with respect to themounting means and in predetermined spaced-apart relation, comprisingthe steps of inserting the terminal leads through an aligning platehaving a plurality of apertures, there being one aperture for eachterminal lead, each aperture being somewhat larger than the crosssection of the terminal lead which extends therethrough so that eachterminal lead may move laterally within its respective aperture,securing the aligning plate to the electrical device, followed byapplying molten solder material to the terminal leads and permitting thesolder to engage the edges of the apertures, followed by placing all ofthe terminal leads simultaneously into a group of spaced-apart conicalaligning members, the apexes of the conical aligning members being in apredetermined spaced-apart relationship desired for the terminal leads,there being one conical recess for each of the terminal leads, thealigning members causing the terminal leads to be positioned in thedesired spaced-apart relationship, followed by retaining the terminalleads in said aligning members until the solder material becomessolidified, followed by removal of the terminal leads from the aligningmembers, the aligning plate thus serving as a support plate retainingthe terminal leads in the desired spacedapart relationship so that theleads may be readily connected to other elements having given spacedrelationships with respect to the mounting means of the board or panel.

7. The method of positioning flexible terminal leads of an electricdevice so that the electric device can be attached to a control circuitpanel in precise predetermined position with the terminal leads locatedin precise predetermined positions with respect to the control circuitsof the panel, comprising forming said terminal leads so that they areapproximately in the desired spaced relationship, followed by relativemovement between the electric device and an alignment member having agroup of hollow conical members, the conical members being open at theends thereof and fixedly maintained in a spaced-apart relation so thatthe apexes thereof are located at positions equal to the desired spacedrelationship of the terminal leads, said movement being in a di- 9rection so that all of the terminal leads simultaneously enter thelarger end of the conical members and move into the small portion of theconical members, attaching the alignment member to the electric deviceso that all of the apexes are in the desired relationship with respectto the device, the extending terminal leads thus being positioned at theapexes of the conical members and all of the terminal leads thus beingsimultaneously positioned and secured in the desired spaced-apartrelation and in the desired relationship with respect to the electricdevice.

8. A method of accurately locating in predetermined positions extendingportions of flexible terminal leads of a transformer provided with acore and a coil and mounting means comprising providing a terminal leadsupport plate, attaching the terminal lead support plate to thetransformer, the terminal lead support plate having a plurality ofapertures therein, there being an extending portion of one terminal leadof the transformer extending through each aperture, each extendingportion being laterally movable within its respective aperture, eachaperture having an edge portion, providing an aligning jig having aplurality of conical recesses, the apexes of the recesses being in thepredetermined spaced-apart relationship which is desired for theterminal leads, the jig having means for causing predeterminedpositioning of the jig with respect to the mounting means of thetransformer, moving the transformer with respect to the aligning jig sothat the extending portions of all of the terminal leads aresimultaneously directed into the apexes of the conical portions,positioning the aligning jig with respect to the transformer so thatsaid portions of the terminal leads are in positions desired for saidportions with respect to the mounting means of the transformer, followedby applying molten solidifiable material to all of said portions of theterminal leads at the portions of the terminal leads which extendthrough the apertures so that the solidifiable material engages the edgeportions of the apertures as well as the terminal leads, followed bypermitting the molten material to solidify thus securing the terminalleads to the terminal lead support plate in desired predeterminedrelative positions and in desired predetermined positions with respectto the mounting means of the transformer.

9. A method of producing a transformer of the type having mounting meansand a core and coil provided with flexible terminal leads so thatextending portions of the terminal leads are accurately disposed inpredetermined positions for mounting of the transformer upon a panel ina predetermined position with the terminal leads precisely positionedwith respect to elements of the panel comprising the provision of analignment plate provided with a plurality of spaced-apart aperturestherethrough, each of the apertures being larger at one end than at theother end, there being one aperture for each of the terminal leads, thesmaller end of the apertures being in the predetermined relative spacedrelationship desired for the terminal leads, each of the terminal leadsbeing only slightly smaller than the opening in the smaller end of theapertures so that the terminal leads are slidably movable through theapertures, attaching the alignment plate to the transformer with theextending portions of the terminal leads inserted through the apertureswith the larger end of the apertures facing the coil and with theterminal leads in the desired predetermined positions with respect tothe mounting means of the transformer, the extending portions of theterminal leads thus being firmly retained in the desired predeterminedpositions with respect to the mounting means of the transformer and onewith respect to the other.

10. A method of aligning and positioning terminal leads of a transformerprovided with a coil and core with the coil extending laterally from thecore comprising providing a terminal lead support plate having anopening to receive the core and having a plurality of apertures, therebeing one aperture for each of the terminal leads of the transformer,followed by relative movement between the transformer and the terminallead support plate so that the terminal lead support plate closelyencompasses a portion of the core adjacent the terminal leads with oneof the terminal leads extending through each of the apertures, each ofthe apertures being larger than the terminal lead which extendstherethrough so that each terminal lead is laterally movable within itsrespective aperture, securing the support plate 'with respect to thecoil and core, followed by aligning all of the leads simultaneously in ajig having a plurality of tapered recesses, there being one taperedrecess to receive each of the terminal leads, the jig being positionedso that the terminal leads located therein are in desired predeterminedlocations one with respect to the other and with respect to otherportions of the transformer, at least some of the leads being movedlaterally within their respective apertures as the leads are placed inthe jig, followed by securing the terminal leads with respect to theterminal lead support plate, followed by relative movement between thejig and the transformer disengaging the terminal leads from the jig, theterminal leads thus being fixed to the support plate and fixed indesired relative positions and with respect to other portions of thetransformer.

11. A method of producing an electric device of the type having a coreand coil with terminal leads extending from the coil so that theterminal leads are precisely disposed and maintained in desiredpredetermined positions one with respect to the others and with respectto the core, comprising providing an aligning plate for approximatelyaligning the terminal leads, the aligning plate having a plurality ofspaced-apart eyelets extending therethrough, each of the eyelets havingan end portion extending from the aligning plate, inserting one of theterminal leads through each of the eyelets, securing the aligning plateto the electric device, followed by aligning and positioningsimultaneously all of the terminal leads in the desired predeterminedpositions one with respect to the others and with respect to otherportions of the electric device by simultaneously passing all of theleads into a jig having tapered recesses and which is held at apredetermined position with respect to portions of the electric device,each of the tapered recesses having an opening at the desired positionfor a lead, the terminal leads being laterally movable within theeyelets, followed by bending said end portions of the eyelets into firmengagement with the terminal leads so that the terminal leads areretained by the eyelets in the aligned positions, followed by removal ofthe leads from the jig leaving the terminal leads secured by thealigning plate in the desired predetermined positions thereof one withrespect to the others and with respect to the electric device.

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